System and method for package construction

ABSTRACT

An optimal package structure and an amount of refrigerant to insert into the package structure are determined based upon product information, consumer preference information, and weather information. The optimal package structure and the amount of refrigerant are an optimized combination that is effective to both protect the product from damage and preserve the product from spoilage. A package is constructed to contain the product according to the optimal package structure and the amount of refrigerant is inserted into the structure.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of the following U.S. ProvisionalApplication No. 62/671,786 filed May 15, 2018, which is incorporatedherein by reference in its entirety.

TECHNICAL FIELD

These teachings relate to product packaging and, more specifically, tothe shipping of frozen or chilled products from shipping sources toshipping destinations using packages that protect the product fromdamage and preserve the product from spoilage.

BACKGROUND

Various types of products are shipped from shipping sources (e.g.,warehouses) to shipping destinations (e.g., homes of consumers). Someproducts that are shipped may need to be kept frozen (or chilled) duringthe shipping process in order to prevent the spoilage of these products.Additionally, many types of products typically need to be protected fromdamage occurring along the shipping route. To take two examples, pizzaor ice cream may need to be kept frozen while being shipped as well asbeing protected from damage that might occur during the shippingprocess.

Standard-sized packages or boxes are often used to ship products. Toprevent spoilage, these standard shipping containers sometimes includepredetermined amounts of refrigerant materials that are used to cool theproducts. That is, the amount of such refrigerant materials cannot bevaried. As for protection from damage, only standard protectionstructures are offered by these previous approaches.

Unfortunately, these previous approaches sometimes resulted in wastedpacking materials and wasted amounts of refrigerant being used since theitem may be, for example, much smaller than the shipping package, andnot need as much of the provided refrigerant in order to be preserved.In other situations, the amount of refrigerant was too little, therebyallowing the product to spoil or otherwise become unusable before theproduct was delivered. In still other examples, the amount ofrefrigerant was adequate, but the structure of the package wasinadequate to protect the product from damage that occurred to thepackage along the shipping route.

BRIEF DESCRIPTION OF THE DRAWINGS

The above needs are at least partially met through the provision ofapproaches that optimize the structure and amount of refrigerant in apackage, wherein:

FIG. 1 comprises a diagram of a system as configured in accordance withvarious embodiments of these teachings;

FIG. 2 comprises a diagram of a system as configured in accordance withvarious embodiments of these teachings;

FIG. 3 comprises a flowchart as configured in accordance with variousembodiments of these teachings;

FIG. 4 comprises a diagram of aspects of a system as configured inaccordance with various embodiments of these teachings;

FIG. 5 comprises a diagram of aspects of a system as configured inaccordance with various embodiments of these teachings;

FIG. 6 comprises a diagram of aspects of a system as configured inaccordance with various embodiments of these teachings;

FIG. 7 comprises a diagram of aspects of a system as configured inaccordance with various embodiments of these teachings;

FIG. 8 comprises a flowchart as configured in accordance with variousembodiments of these teachings;

FIG. 9 comprises a flowchart as configured in accordance with variousembodiments of these teachings;

FIG. 10 comprises a diagram of aspects of a system as configured inaccordance with various embodiments of these teachings;

FIG. 11 comprises a diagram of aspects of a system as configured inaccordance with various embodiments of these teachings;

FIG. 12 comprises a diagram of aspects of a system as configured inaccordance with various embodiments of these teachings;

FIG. 13 comprises a diagram of aspects of a system as configured inaccordance with various embodiments of these teachings;

FIG. 14 comprises a diagram of aspects of a system as configured inaccordance with various embodiments of these teachings.

DETAILED DESCRIPTION

Generally speaking, a system obtains various types of informationincluding customer preferences about how the customer wants theirproduct (e.g., a perishable product) delivered (e.g., time of day),physical characteristics of the product (e.g., dimensions or cold chainrequirements), and/or the weather data along the delivery route (e.g.,hot weather). Using this information, the package structure and amountof refrigerant placed in the product structure are dynamically optimizedso as to both provide adequate protection for the product and toadequately cool or preserve the product during the shipping and deliveryprocess.

In many of these embodiments, a system that is configured to optimizepackage structure and an amount of refrigerant for the shipment ofrefrigerated products includes a user interface, a database, at leastone sensor, and a control circuit. The user interface is configured toreceive consumer preference information from a customer. The customerpreference information identifies one or more preferences of thecustomer concerning the timing or method of shipping a product from ashipping source to a shipping destination according to a delivery route.Other examples are possible.

The database is coupled to the user interface and is configured to storethe customer preference information. The database is also configured tostore product information. The product information may be physicalcharacteristics or cooling requirements of the product. Other examplesare possible.

The sensor is configured to obtain weather information concerningweather conditions occurring along the delivery route. For example, thesensor may obtain temperature, wind, pressure, or precipitation datarelating to conditions occurring along the route.

The control circuit is coupled to the database, the user interface, andthe at least one sensor. The control circuit is configured to determinean optimal package structure and an amount of refrigerant to insert intothe package structure based upon the product information, the consumerpreference information, and the weather information. The optimal packagestructure and the amount of refrigerant are selected so as to be anoptimized combination that is effective to both protect the product fromdamage and preserve the product from spoilage.

The package construction apparatus is coupled to the control circuit.The package contraction apparatus is configured to construct a packageto contain the product according to the optimal package structure and toinsert the amount of refrigerant into the structure as determined by thecontrol circuit.

In aspects, the optimized package structure is designed so as tooptimize a thickness of the package or a shape of the package. Othercharacteristics may also be optimized. In some examples, the optimalpackage structure is a honeycomb configuration. In examples, thehoneycomb configuration includes gaps into which the refrigerant isselectively inserted.

In other aspects, the optimal package structure includes a plurality ofcompartments to hold a plurality of products. That is, the overallpackage is divided into multiple compartments. The multiple compartmentsmay have varying protection structures and varying amounts ofrefrigerant.

The products may be a wide variety of types of products. In examples,the product may be a frozen product, a refrigerated product, or achilled product. Other examples of products are possible.

In some examples, the refrigerant is dry ice. Other examples ofrefrigerants (or combinations of refrigerant materials) may also beused.

The package construction apparatus can utilize a variety of differentprocesses and can be configured in a number of different ways. In oneexample, the package construction apparatus utilizes a printing processto construct the package.

In still others of these examples, the physical characteristics of theproduct include product dimensions, product weights, product types, orcold chain requirements. Other examples are possible.

The package (or the components of the package) can be disassembled andre-used. For example, the walls of a first package (having a honeycombstructure) can be disassembled from the first package and re-assembledinto new packages.

In others of these embodiments, consumer preference information iscollected from a customer. The customer preference informationidentifies one or more preferences of the customer concerning the timingor method of shipping a product from a shipping source to a shippingdestination according to a delivery route.

The customer preference information is stored in a database. Thedatabase also stores product information such as the physicalcharacteristics or cooling requirements of the product. Weatherinformation concerning weather conditions that occur along the deliveryroute is also collected.

An optimal package structure and an amount of refrigerant to insert intothe package structure are determined based upon the product information,the consumer preference information, and the weather information. Theoptimal package structure and the amount of refrigerant are an optimizedcombination that is effective to both protect the product from damageand preserve the product from spoilage. A package is constructed tocontain the product according to the optimal package structure and theamount of refrigerant is inserted into the structure.

Referring now to FIG. 1, one example of a system 100 that optimizes thestrength of a package and the amount of refrigerant in the package isdescribed. The system 100 includes a shipment center 108 (where packagesare created and from which packages are shipped). The shipment center108 may be associated with or included within a warehouse, distributioncenter, retail store, or some other stand-alone location. In otherexamples, the shipment center 108 may be located at a customer location(e.g., at a customer home, business, school, or office). The shipmentcenter 108 may be disposed at or associated with other locations aswell.

Various electronic and/or mechanical elements are disposed at theshipment center 108. More specifically, a first user interface 102, adatabase 104, a control circuit 106, and a package constructionapparatus 110 (that constructs a package 114 into which a product 112 isinserted) are disposed at the shipment center 108. Once the product 112is inserted into the package 114, the package 114 is placed into adelivery vehicle 122, which carries the package 114 along a deliveryroute 126 to a shipping destination 124. Sensors 118 and 120 aredisposed along the delivery route 126. A network 116 is coupled to thesensors 118, 120, a second user interface 103 (located at the shippingdestination 124), and the control circuit 106. The shipping destination124 may be a retail store, customer's home, office, business, school,apartment building, or a distribution center to mention a few examples.

The first user interface 102 is an electronic device that allow a userto enter information such as product information. In addition, theproduct information can be downloaded from some other location (e.g.,directly from a manufacturer). In examples, the first user interface 102is included at or incorporated with a cellular phone, smart phone,personal computer, or laptop to mention a few examples. The first userinterface 102 may be a touchscreen, keyboard, computer mouse, or acombination of these or other elements. In some aspects, the userinterface 102 is or provides an electronic connection to an outside datasource.

The second user interface 103 is disposed at or in the vicinity of theshipping destination 124 and allows a customer to enter their shippingpreferences. In examples, the user interface 103 is disposed at orincorporated with a cellular phone, smart phone, personal computer, orlaptop to mention a few examples. The second user interface 103 may be atouchscreen, keyboard, computer mouse, or a combination of these orother elements.

The database 104 is any type of memory storage device. In examples, thedatabase 104 stores the customer preference information, the productinformation, and the weather information.

The control circuit 106 is coupled to the user interface 102, thedatabase 104, the package construction apparatus 110, and the network116 (possibly via a transceiver circuit that is disposed at the shipmentcenter 108). It will be appreciated that as used herein the term“control circuit” refers broadly to any microcontroller, computer, orprocessor-based device with processor, memory, and programmableinput/output peripherals, which is generally designed to govern theoperation of other components and devices. It is further understood toinclude common accompanying accessory devices, including memory,transceivers for communication with other components and devices, etc.These architectural options are well known and understood in the art andrequire no further description here. The control circuit 106 may beconfigured (for example, by using corresponding programming stored in amemory as will be well understood by those skilled in the art) to carryout one or more of the steps, actions, and/or functions describedherein.

As mentioned, the package construction apparatus 110 constructs thepackage 114 into which a product 112 is inserted. The package 114 isconstructed of any suitable material (e.g., cardboard, honeycomb,printed in layers, to mention a few examples). Packing materials mayalso be inserted into the package 114 and according to these approaches,the amount and positioning of the packing materials can also beadjusted, for example, to allow optimal cooling (e.g., by providingchannels to circulate cold air within the package 114 and/or to providestructural protection).

The product 112 may be of any type, for example, a grocery product, drygoods, appliance, book, health care product, personal hygiene product,electronics, frozen, chilled, to mention a few examples. Other examplesare possible.

The package construction apparatus 110 is any type of machine (orcombination of machines) that constructs packages. In examples, thepackage construction apparatus 110 may be a device that uses a printingprocess to print layers of materials to construct the package 114. Thepackage construction apparatus 110 receives the package design from thecontrol circuit 106 and constructs a package according to this design.For example, the design may specify the thickness, length, width, depth,shape, and/or contours of the package. The amount of refrigerant is alsoreceived from the control circuit 106. The refrigerant may, in oneexample, be dry ice. Other examples of refrigerant are possible.

In some examples, the placement of the refrigerant within the package114 may also be specified. For example, the refrigerant may be uniformlypositioned throughout the package structure (e.g., in empty voids orspaces in the package structure). In other examples, the refrigerant maybe positioned closely to the product 112, while portions of the package114 further away from the product may have little or no refrigerant.

The network 116 is any network or combination of electronic networkssuch as the internet, computer networks, wide area networks, local areanetworks, Wi-Fi networks, or any other type of electronic network. Thenetwork 116 allows information to be received at the control circuit 106from the second user interface 103, and sensors 118 and 120.

The sensors 118 and 120 are any type of sensors that collect weatherdata. For example, the sensors 118 and 120 may be or includethermometers (to measure temperature), or pressure sensors (to senseatmospheric pressure). Other examples of sensors that obtain other typesof measurements or values are possible.

The vehicle 122 is any type of vehicle (e.g., aerial drone, automatedground vehicle, car, truck, train, or ship) that can be utilized todeliver packages. The delivery route 126 is any delivery route or path(e.g., roads, bridges, railroad tracks, or combinations of these andother paths that allow traversing by the vehicle 122).

In one example of the operation of the system of FIG. 1, the first userinterface 102 and/or second user interface 103 are configured to receiveconsumer preference information from a customer. The user interface 102may allow information to be entered at the shipment center 108. Thesecond user interface 103 may be utilized when the customer is at aremote site such as the shipping destination 124 (or some otherlocation). This information may be sent to the shipment center 108 viathe network 116.

The database 104 stores the customer preference information, the productinformation, and the weather information.

The control circuit 106 is configured to determine an optimal packagestructure and an amount of refrigerant to insert into the packagestructure based upon the product information, the consumer preferenceinformation, and the weather information. The optimal package structureand the amount of refrigerant are selected so as to be an optimizedcombination that is effective to both protect the product 112 fromdamage and preserve the product 112 from spoilage.

The package contraction apparatus 110 is configured to construct thepackage 114 to contain the product 112 according to the optimal packagestructure and to insert the amount of refrigerant into the structure asdetermined by the control circuit 106.

Referring now to FIG. 2, another example of a system 200 that optimizesthe strength of a package and the amount of refrigerant in the packageis described.

The system 200 includes a central processing center 207 (including afirst user interface 202, a database 204, and a control circuit 206) anda shipment center 208. The central processing center may be at anycentralized location such as a headquarters or home office. The shipmentcenter 208 (where packages are created and from which the packages areshipped) may be associated with or included within a warehouse,distribution center, or retail store. In other examples, the shipmentcenter 208 may be located at a customer location (e.g., at a customerhome, business, school, or office). The shipment center 208 may bedisposed at other locations as well.

At the shipment center 208 is disposed a package construction apparatus210 that constructs a package 214 into which a product 212 is inserted.Once the product 212 is inserted into the package 214, the package isplaced into a delivery vehicle 222, which carries the package 214 alonga delivery route 226 to a shipping destination 224. Sensors 218, 220 aredisposed along the delivery route 226. A network 216 is coupled to thesensors 218, 220, a second user interface 203, the package constructionapparatus 210, and the control circuit 206.

A difference between the example of FIG. 1 and the example of FIG. 2 isthat different system elements are disposed at different locations. Morespecifically, in the example of FIG. 1, the first user interface,database, control circuit and package construction apparatus aredisposed at a shipping center. On the other hand, in the example of FIG.2, the first user interface, database, and control circuit are disposedat a central processing center, and the package construction apparatusis disposed at a remote shipping center. It will be appreciated thatthese are only two examples of the disposition of various systemcomponents and that other dispositions are possible.

The first user interface 202 is an electronic device that allows a userto enter information such as product information. In addition, theproduct information can be downloaded from some other location (e.g.,directly from a manufacturer). In examples, the first user interface 202is included at or incorporated with a cellular phone, smart phone,personal computer, or laptop to mention a few examples. The first userinterface 202 may be a touchscreen, keyboard, computer mouse, or acombination of these or other elements. In some aspects, the first userinterface 202 is an electronic connection to an outside data source.

The second user interface 203 is disposed at or in the vicinity of theshipping destination 224 and allows a customer to enter their shippingpreferences. In examples, the second user interface 203 is included ator incorporated with a cellular phone, smart phone, personal computer,or laptop to mention a few examples. The second user interface 203 maybe a touchscreen, keyboard, computer mouse, or a combination of these orother elements.

The database 204 is any type of memory storage device. In examples, thedatabase 204 stores the customer preference information, the productinformation, and the weather information.

The control circuit 206 is coupled to the first user interface 202, thedatabase 204 and the network 216 (possibly via a transceiver circuitthat is disposed at the shipment center 208). It will be appreciatedthat as used herein the term “control circuit” refers broadly to anymicrocontroller, computer, or processor-based device with processor,memory, and programmable input/output peripherals, which is generallydesigned to govern the operation of other components and devices. It isfurther understood to include common accompanying accessory devices,including memory, transceivers for communication with other componentsand devices, etc. These architectural options are well known andunderstood in the art and require no further description here. Thecontrol circuit 206 may be configured (for example, by usingcorresponding programming stored in a memory as will be well understoodby those skilled in the art) to carry out one or more of the steps,actions, and/or functions described herein.

As mentioned, the package construction apparatus 210 constructs thepackage 214 into which a product 212 is inserted. The package 214 isconstructed of any suitable material (e.g., cardboard, honeycomb,printed in layers, to mention a few examples). Packing materials mayalso be inserted into the package 214 and according to these approaches,the amount and positioning of the packing materials can also beadjusted, for example, to allow optimal cooling (e.g., by providingchannels to circulate cold air within the package 214 and/or to providestructural protection).

The product 212 may be of any type, for example, a grocery product, drygoods, appliance, book, health care product, personal hygiene product,electronics, frozen, chilled, to mention a few examples. Other examplesare possible.

The package construction apparatus 210 is any type of machine (orcombination of machines) that constructs packages. In examples, thepackage construction apparatus 210 may be a device that uses a printingprocess to print layers of materials to construct the package 214. Thepackage construction apparatus 210 receives the package design from thecontrol circuit 206 and constructs a package according to this design.For example, the design may specify the thickness, length, width, depth,shape, and/or contours of the package. The amount of refrigerant is alsoreceived from the control circuit 206. The refrigerant may, in oneexample, be dry ice. Other examples of refrigerant are possible.

In some examples, the placement of the refrigerant within the package214 may also be specified. For example, the refrigerant may be uniformlypositioned throughout the package structure (e.g., in empty voids orspaces in the package structure). In other examples, the refrigerant maybe positioned closely to the product 212, while portions of the package214 further away from the product may have little or no refrigerant.

The network 216 is any network or combination of electronic networkssuch as the internet, computer networks, wide area networks, local areanetworks, Wi-Fi networks, or any other type of electronic network. Thenetwork 216 allows information to be received at the control circuit 206from the second user interface 203, and sensors 218 and 220. The network216 also connects the control circuit 206 with the package constructionapparatus 210.

The sensors 218 and 220 are any type of sensors that collect weatherdata. For example, the sensors 218 and 220 may be or includethermometers (to measure temperature), or pressure sensors (to senseatmospheric pressure). Other examples of sensors are possible.

The vehicle 222 is any type of vehicle (e.g., aerial drone, automatedground vehicle, car, truck, train, or ship) that can be utilized todeliver packages. The delivery route 226 is any delivery route or path(e.g., roads, bridges, railroad tracks, or combinations of these andother paths that allow traversing by the vehicle 222).

In one example of the operation of the system of FIG. 2, the first userinterface 202 and/or second user interface 203 are configured to receiveconsumer preference information from a customer. The first userinterface 202 may allow information to be entered at the shipment center208. The second user interface 203 may be utilized when the customer isat a remote site such as the shipping destination 224. This informationmay be sent to the shipment center 208 via the network 216.

The database 204 stores the customer preference information, the productinformation, and the weather information.

The control circuit 206 is configured to determine an optimal packagestructure and an amount of refrigerant to insert into the packagestructure based upon the product information, the consumer preferenceinformation, and the weather information. The optimal package structureand the amount of refrigerant are selected so as to be an optimizedcombination that is effective to both protect the product 212 fromdamage and preserve the product 212 from spoilage.

The package contraction apparatus 210 is configured to construct thepackage 214 to contain the product 212 according to the optimal packagestructure and to insert the amount of refrigerant into the structure asdetermined by the control circuit 206.

Referring now to FIG. 3, one example of an approach that creates anoptimal package design, which optimizes the strength of a package andthe amount of refrigerant in the package is described. At step 302,consumer preference information is collected from a customer and storedin a database. The customer preference information identifies one ormore preferences of the customer concerning the timing or method ofshipping a product from a shipping source to a shipping destinationaccording to a delivery route (e.g., next day air delivery).

At step 304, weather information concerning weather conditions occurringalong the delivery route is collected and stored in the database. Theweather information may be obtained by various sensors that are deployedalong the delivery route. For example, the sensors may be thermometers,wind speed measurement devices, or barometric pressure sensors. Othertypes of sensors are possible.

At stop 306, product information is stored in the database. The productinformation is physical characteristics or cooling requirements of theproduct. In aspects, the product information may be electronicallydownloaded from a manufacturer, distributor, or other source.

At step 308, an optimal package structure and an amount of refrigerantto insert into the package structure are determined based upon theproduct information, the consumer preference information, and theweather information. The optimal package structure and the amount ofrefrigerant is an optimized combination that is effective to bothprotect the product from damage and preserve the product from spoilage.

At step 310, a package is constructed to contain the product accordingto the optimal package structure and inserting the amount of refrigerantinto the structure. Various types of machines can be used to contractthe package. For example, package printing approaches well known tothose skilled in the art can be utilized. The machines receive thepackage structure and convert this information or instructions (i.e.,specifying the package design) into physical actions that are effectiveto build or construct a corresponding package. Additionally, themachines receive instructions as to the amount of refrigerant to insertand are configured to insert this amount of refrigerant into the packagestructure. In further aspects, the machines may receive instructionsthat specify the location in the package structure where the refrigerantis to be inserted.

At step 312, the product is inserted into the package and shipped. Theshipment may be made via any type of delivery vehicle such as a car,truck, train, or ship to mention a few examples.

Referring now to FIG. 4, one example of an approach for mapping productsto protection levels is described. A matrix 452 is divided into columns454 and rows 456. The columns 454 represent structural protectionoffered by the product and are divided into high, medium, and low. By“high” protection, it is meant the product is extremely breakable andsusceptible to damage and that the maximum amount of protection shouldbe used. By “medium” protection, it is meant that the product stillneeds some protection and may be susceptible to damage, but that thestructural protection need not be maximized. In other words, a moderateamount of protection is needed. By “low” protection, it is meant that aminimal amount of protection is needed. In other words, little or noprotection is needed (other than a box to enclose the product) for theproduct to reach the destination.

The rows 456 represent the amount of refrigeration provided by thepackage and are divided into high, medium, and low. By a “high” amount,it is meant the product is extremely susceptible to spoilage and(potentially) extra refrigerant is needed to keep the product coldenough so that it will be preserved when being transported to theshipping destination. By a “medium” amount, it is meant that a moderateamount of refrigerant is needed. Although the amount of refrigerant isnot maximized, some amount of refrigerant is still needed. By a “low”amount, it is meant that little or no refrigerant is needed to preservethe product when it is shipped to the destination.

The matrix 452 consists of cells 401, 402, 403, 404, 405, 406, 407, 408,and 409. Each cell corresponds to a row and column, and consequently alevel of structural protection and amount of refrigeration provided. Forinstance, cell 401 represents products needing packages that offer highstructural protection and provide high amounts of refrigeration. Each ofthe cells is suitable for different types of product.

Cell 401 is for products such as chocolate covered ice cream products(e.g., Christmas tree shaped chocolate products). Cell 402 representsproducts such as frozen fruit. Cell 403 is for products such as frozenmeat.

Cell 404 is for products such as cooked appetizers. Cell 405 representsproducts such as frozen vegetables. Cell 406 is for products such asblocks of cheese.

Cell 407 is for products such as ordinary ice cream (e.g., not coveredby chocolate). Cell 408 represents products such as refrigerated meat.Cell 409 is for products such as frozen juice concentrate.

It will be appreciated that these are examples only, and that otherexamples are possible. It can be seen that a product type may bedetermined, mapped to a particular cell, and then an appropriate packageconstructed for the product.

Referring now collectively to FIGS. 5-9, one example of theimplementation of these approaches is described.

Referring especially now to FIG. 5, one example of how productinformation, customer preference information, and weather information ismapped into an amount of refrigerant to be inserted into a package isdescribed. As shown in this example, product information 502, customerpreference information 506, and weather (temperature along the route)information 508 is received or obtained. In this case, the productinformation 502 indicates that the product is frozen. The customerpreference information 506 indicates that the customer desires a slowdelivery speed (e.g., more than X-day delivery time frame, where X is aninteger value). The weather information 508 indicates the temperaturealong the route is hot (greater than 90 degrees Fahrenheit). Given theseinputs, a refrigerant amount 510 is obtained indicating a high amount ofrefrigerant is needed.

It will be appreciated that this is only one example of a mapping. Otherinputs will potentially produce different amounts (e.g., low or medium)amounts of refrigerant. Moreover, the terms high, medium, and low map tonumerical values. For instance, “high” may always map to a firstpredetermined amount of refrigerant, “medium” to a second predeterminedamount of refrigerant, and “low” may map to a third predetermined amountof refrigerant. By “amount,” it is meant volume, weight, mass or anyother characteristic that describes how much refrigerant is to beinserted or used with the package. It will also be understood that morethan three amount levels (e.g., high, medium, and low) may be used. Forexample, an equation may be utilized that assigns points to input, andinputs entered into this equation, which yields an amount ofrefrigerant.

Returning to FIG. 5, an example of a mapping that determines the degreeof protection to be offered by the package is described. In a firstmapping 520, a product that has been classified as “fragile” is mappedto a package with a high package strength. In a second mapping 522, aproduct that has been classified as “semi-fragile” is mapped to apackage with a medium package strength. In a third mapping 524, aproduct that has been classified as “soft” is mapped to a package with alow package strength.

It will be appreciated that “high,” “medium,” and “low” package strengthstructures may be defined according to a variety of differentcharacteristics. For example, each of these characterizations may beassociated with a predetermined package thickness, a package with acertain structure (e.g., honeycomb structure), or package constructed ofa particular material (e.g., cardboard).

Referring now to FIG. 6, one example of a mapping from (1) the desiredamount of refrigerant, and (2) the desired package strength to aparticular package design is described. The desired amount ofrefrigerant and the desired package strength may be determined accordingto the approach of FIG. 5. These values are mapped to a particularpackage design that is created by specific sets of instructions.

In one example, once the amount of refrigerant and amount of structuralprotection are determined, a table or matrix 600 maps these values todifferent groups of computer instructions that are executed by a machineto create the package. For instance, the instructions may create apackage of certain dimensions that depend upon the height, length,width, and/or shape of the product. The package may have a wallthickness that depends upon the amount of protection (e.g., high,medium, or low) that is desired. The package may have an amount ofrefrigerant inserted that depends upon the amount of cooling needed. Theinstructions may be computer implemented instructions (e.g., computercode) that is utilized by a machine that actually creates the package.

It will be appreciated that instead of selecting a particular group ofinstructions, a predetermined package design may be determined. Morespecifically, once the amount of refrigerant and amount of structuralprotection for the package are determined, the table 600 may mapdirectly to a predetermined package design, with the package havingpredetermined dimensions (e.g., height, length, width, and wallthickness) and having a predetermined amount of refrigerant in apredetermined distribution pattern.

As shown in the mapping table 600, package strengths 602, 604, and 606and amount of refrigerants 608, 610, and 612 are mapped to differentinstructions (Instructions A, B, C, D, E, F, G, H, and I that are shownin the various cells of the table 600). For example, a high packagestrength 602 and a high amount of refrigerant 608 map to Instructions A.Once the instructions are selected, then these are executed to determinea pattern, design, or plan for the package. The plan is sent to amachine that constructs the package according to the design or plan. Theinstructions may use values of various parameters stored in memory, suchas the parameters illustrated in FIG. 7.

Referring now to FIG. 7, one example of a memory structure 700 isdescribed. The memory structure 700 includes an air temperature 702, adelivery speed 704, a temperature requirement 706, a product type 708,dimensions 710, a high package thickness (HT) value 712, a mediumpackage thickness (MT) value 714, a low package thickness (LT) value716, a high density (HD) refrigerant value 718, a medium density (MD)refrigerant value 720, and a low density (LD) refrigerant value 722.These values are obtained from different sources, stored in the memory,and used to determine a package design.

The air temperature 702 is the air temperature as measured by thedelivery vehicle. The air temperature 702 may be obtained by sensorsalong a delivery route.

The delivery speed 704 is the delivery speed selected by the customer.For example, the delivery speed may be set to be fast, normal, or slow.Fast may mean overnight, normal may be 1-3 business days, and slow maymean greater than 3 business days in some examples.

The temperature requirement 706 may specify cold chain requirements forthe product. For example, the product may be required to be kept at orbelow a predetermined temperature.

The product type 708 may be a specific product type such as frozenvegetables or cooled beverage. The dimensions 710 may be the physicaldimensions of the product, including overall product dimensions. In someexamples, the dimensions 710 are exact dimensions that include or definethe product shape. The dimensions can be of any convenient measurementunit.

The high package thickness (HT) value 712, medium package thickness (MT)value 714, and low package thickness (LT) value 716 are numerical values(that can be adjusted) of package wall thicknesses. These values can beof any convenient measurement unit.

The high density (HD) refrigerant value 718, medium density (MD)refrigerant value 720, and low density (LD) refrigerant value 722 aredensity values of refrigerant that is to be inserted into the package.

Referring now to FIG. 8, one example of an instruction set is described.FIG. 8 represents “Instructions A” from the table 600 of FIG. 6.

At step 802, product dimensions may be obtained. The product dimensionsmay be the length, width, and depth (or thickness) of the product.Additionally, the shape of the product may be considered as defined bythe dimensions. For example, the dimensions may not only define straightlines, but non-rectangular shapes such as various types of curves. Totake one example, the dimensions of a bottle of orange juice may beoverall dimensions of the bottles (e.g., length, width, and thickness).However, in other aspects, the dimensions may specify the exact shape(e.g., including the curves) of the bottle. In other words, thesedimensions would include overall dimensions, and also include dimensionsand locations for curves in the bottle design, places where thethickness of the bottle varied (e.g., the bottle is thicker on bottomthan on the top).

At step 804, a preliminary package design is obtained according to theproduct dimensions and with a honeycomb structure with a high thickness(HT). HT may be set to a predetermined value, for example, in inches orcentimeters. In aspects, the HT value may be the high package thickness(HT) value 712. The preliminary package design may be of a standardshape or designed to fit the shape and contours of the product.

At step 806, the preliminary design is finalized by determining anamount and pattern of refrigerant (e.g., dry ice) to be inserted intothe package structure. The refrigerant is inserted with a high density(HD) configuration. In aspects, the high density (HD) refrigerant value718 of FIG. 7. The HD value may be set to some numerical value, such asthe amount of refrigerant in a cubic volume of space. For example, theHD value may be set to fill all empty spaces in the honeycomb structureor a predetermined number of spaces in the honeycomb structure (e.g., 80percent of the volume of the structure).

The refrigerant may also be selectively spaced within the package basedupon product type (e.g., according to the product type 708). Forinstance, a bottle of orange juice may be shipped and the refrigerantmay be placed in the spaces of the honeycomb structure that areimmediately adjacent to the bottle. In another example, the density ofrefrigerant may be varied in the package. For example, a first densityof refrigerant may be deposited in areas or volumes immediately adjacentto the product, but a second (and lower) density deposited in areas orvolumes that are not immediately adjacent to the product. The first andsecond densities may take on various values (including zero for thesecond density) as long as the first density is greater than the seconddensity.

The result of completing step 806 is a final product design. The finalproduct design may be in any electronic form such as a data structure,computer instructions, a script, or some combinations of these elements.

Referring now to FIG. 9, another example of an instruction set isdescribed. FIG. 9 represents “Instructions I” from the table of FIG. 6.

At step 902, product dimensions may be obtained. The product dimensionsmay be the length, width, and depth (or thickness) of the product.Additionally, the shape of the product may be considered as defined bythe dimensions. As with the example of FIG. 8, the dimensions may notonly define straight lines, but include non-rectangular shapes such asshapes with various types of curves.

At step 904, a preliminary package design is obtained according to theproduct dimensions and with a honeycomb structure with a low thickness(LT). LT may be set to a predetermined value, for example, in inches orcentimeters. In aspects, the LT value may be the low package thickness(LT) value 716.

At step 906, the preliminary design is finalized by determining anamount and pattern of refrigerant (e.g., dry ice) to be inserted intothe package structure. The refrigerant is inserted with a low density(LD) configuration. In aspects, the low density (LD) refrigerant value722 of FIG. 7. The LD value may be set to some numerical value, such asthe amount of refrigerant in a cubic volume of space. For example, theLD value may be set to fill all empty spaces (with a small amount ofrefrigerant) in the honeycomb structure or a predetermined number ofspaces in the honeycomb structure (e.g., 20 percent of the volume of thestructure with a higher amount of refrigerant in each space). As withthe example of FIG. 8, the refrigerant may also be selectively spacedwithin the package based upon product type (e.g., according to theproduct type 708 or dimensions).

The result of completing step 906 is a final product design. The finalproduct design may be in any electronic form such as a data structure,computer instructions, a script, or some combinations of these elements.

Referring now to FIG. 10, one example of a package design with a highdensity of refrigerant incorporated into the design is described. Thepackage design comprises a honeycomb structure 1000 with void volumes1002 separated by walls. Refrigerant (e.g., dry ice) 1004 is insertedinto the void volumes 1002. Since the example of FIG. 10 is a designwith high amounts of refrigerant 1004, all the void volumes 1002 haverefrigerant 1004 inserted.

Referring now to FIG. 11, one example of a package design with a mediumdensity of refrigerant incorporated into the design is described. Thepackage design comprises a honeycomb structure 1100 with void volumes1102 separated by walls. Refrigerant (e.g., dry ice) 1104 is insertedinto the void volumes 1102. Since the example of FIG. 11 is a designwith medium amounts of refrigerant 1104, only some of the void volumes1102 (a number less than the high-density configuration of FIG. 10) haverefrigerant 1104 inserted.

Referring now to FIG. 12, one example of a package design with a lowdensity of refrigerant incorporated into the design is described. Thepackage design comprises a honeycomb structure 1200 with void volumes1202 separated by walls. Refrigerant (e.g., dry ice) 1204 is insertedinto the void volumes 1202. Since the example of FIG. 12 is a designwith low amounts of refrigerant 1204 (an amount less than the mediumdensity configuration), very few of the void volumes 1202 haverefrigerant 1204 inserted.

Referring now to FIG. 13, an example of a non-honeycomb packagestructure is described. A structure 1300 includes void volumes 1302separated or defined by walls. In contrast to the examples of FIGS.10-12, the example of FIG. 13 is similar in structural integrity tobubble-wrap. Selected void volumes 1302 may be filled with refrigerant(e.g., dry ice) 1304. Thus, the structure of FIG. 13 may itself beinserted into another package (e.g., a cardboard box). Consequently, oneof the structures (e.g., the cardboard box) provides much of thestructural protection, while the other structure (the structure 1300)holds the refrigerant 1304.

Referring now to FIG. 14, one example of a package design 1400 withmultiple compartments 1402, 1404, 1406, 1408, 1410, and 1412 isdescribed. Each of the compartments 1402, 1404, 1406, 1408, 1410, and1412 may have different dimensions and be surrounded by differentprotection structures (e.g., honeycomb structures of differentthicknesses) and enclose different types of products. Additionally, eachof the compartments 1402, 1404, 1406, 1408, 1410, and 1412 may havevarying amounts and/or densities of refrigerant surrounding thecompartment. In aspects, the temperature varies between the differentcompartments. For example, one of the compartments 1402, 1404, 1406,1408, 1410, and 1412 may be maintained at 32 degrees F., another one ofthe compartments 1402, 1404, 1406, 1408, 1410, and 1412 may bemaintained at −10 degrees F., and still another one of the compartments1402, 1404, 1406, 1408, 1410, and 1412 is maintained at 0 degrees F.

In addition, certain ones of the compartments serve to add/provideprotection and/or refrigerant to benefit others of the compartments. Forexample, the compartment 1402 is completely surrounded by the othercompartments 1404, 1406, 1408, 1410, and 1412. The compartments 1404,1406, 1408, 1410, and 1412 provide protection for the contents ofcompartment 1402. Similarly, the other compartments 1404, 1406, 1408,1410, and 1412 help cool the compartment 1402 by insulating thecompartment 1402 and by adding to the refrigerant that directlysurrounds the compartment 1402.

Those skilled in the art will recognize that a wide variety ofmodifications, alterations, and combinations can be made with respect tothe above described embodiments without departing from the scope of theinvention, and that such modifications, alterations, and combinationsare to be viewed as being within the ambit of the inventive concept.

What is claimed is:
 1. A system that is configured to optimize packagestructure and an amount of refrigerant for the shipment of refrigeratedproducts, the system comprising: a user interface configured to receiveconsumer preference information from a customer, the customer preferenceinformation identifying one or more preferences of the customerconcerning the timing or method of shipping a product from a shippingsource to a shipping destination according to a delivery route; adatabase that is coupled to the user interface and is configured tostore the customer preference information, the database also beingconfigured to store product information, the product information beingphysical characteristics or cooling requirements of the product; atleast one sensor that is configured to obtain weather informationconcerning weather conditions occurring along the delivery route; acontrol circuit coupled to the database, the user interface, and the atleast one sensor, the control circuit being configured to determine anoptimal package structure and an amount of refrigerant to insert intothe package structure based upon the product information, the consumerpreference information, and the weather information, the optimal packagestructure and the amount of refrigerant being an optimized combinationthat is effective to both protect the product from damage and preservethe product from spoilage; a package construction apparatus that iscoupled to the control circuit, the package construction apparatusconfigured to construct a package to contain the product according tothe optimal package structure and to insert the amount of refrigerantinto the structure as determined by the control circuit.
 2. The systemof claim 1, wherein the optimized package structure is designed so as tooptimize a thickness of the package or a shape of the package.
 3. Thesystem of claim 1, wherein the optimal package structure is a honeycombconfiguration.
 4. The system of claim 3, wherein the honeycombconfiguration includes gaps into which the refrigerant is selectivelyinserted.
 5. The system of claim 1, wherein the optimal packagestructure includes a plurality of compartments to hold a plurality ofproducts.
 6. The system of claim 1, wherein the product is selected fromthe group consisting of a frozen product, a refrigerated product, or achilled product.
 7. The system of claim 1, wherein the refrigerant isdry ice.
 8. The system of claim 1, wherein the package constructionapparatus utilizes a printing process.
 9. The system of claim 1, whereinthe physical characteristics of the product includes product dimensions,product weights, product types, or cold chain requirements.
 10. A methodto optimize package structure and an amount of refrigerant for theshipment of refrigerated products, the method comprising: collectingconsumer preference information from a customer, the customer preferenceinformation identifying one or more preferences of the customerconcerning the timing or method of shipping a product from a shippingsource to a shipping destination according to a delivery route; storingthe customer preference information in a database, the database alsostoring product information, the product information being physicalcharacteristics or cooling requirements of the product; obtainingweather information concerning weather conditions occurring along thedelivery route; determining an optimal package structure and an amountof refrigerant to insert into the package structure based upon theproduct information, the consumer preference information, and theweather information, the optimal package structure and the amount ofrefrigerant being an optimized combination that is effective to bothprotect the product from damage and preserve the product from spoilage;constructing a package to contain the product according to the optimalpackage structure and inserting the amount of refrigerant into thestructure.
 11. The method of claim 10, wherein the optimized packagestructure is designed so as to optimize a thickness of the package or ashape of the package.
 12. The method of claim 10, wherein the optimalpackage structure is a honeycomb configuration.
 13. The method of claim12, wherein the honeycomb configuration includes gaps into which therefrigerant is selectively inserted.
 14. The method of claim 10, whereinthe optimal package structure includes a plurality of compartments tohold a plurality of products.
 15. The method of claim 10, wherein theproduct is selected from the group consisting of a frozen product, arefrigerated product, or a chilled product.
 16. The method of claim 10,wherein the refrigerant is dry ice.
 17. The method of claim 10, whereinconstructing the package utilizes a printing process.
 18. The method ofclaim 10, wherein the physical characteristics of the product includesproduct dimensions, product weights, product types, or cold chainrequirements.